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Self-cleaning substrates and methods for making the same

  • US 8,617,665 B2
  • Filed: 09/29/2009
  • Issued: 12/31/2013
  • Est. Priority Date: 08/03/2009
  • Status: Expired due to Fees
First Claim
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1. A method comprising:

  • (a) first producing a colored aluminum sheet product, the first producing step comprising;

    (i) first roll coating a colored coating liquid onto an aluminum alloy sheet; and

    (ii) first converting the colored coating liquid into a colored layer, wherein the colored layer is located on an outer surface of the aluminum alloy sheet;

    (b) second producing an intermediate aluminum sheet product, the second producing step comprising;

    (i) second roll coating an inorganic barrier coating liquid onto at least a portion of the colored layer of the colored aluminum sheet product, wherein the inorganic barrier coating liquid is in the form of an aqueous solution comprising silica; and

    (ii) second converting the inorganic barrier coating liquid into an inorganic barrier layer, wherein, after the second converting step, the inorganic barrier layer is located on at least a portion of the colored layer; and

    (c) third producing a colored self-cleaning aluminum sheet product, the third producing comprising;

    (i) third roll coating a portion of an aqueous-based self-cleaning coating precursor liquid onto at least a portion of the inorganic barrier layer of the intermediate aluminum sheet product;

    wherein, the self-cleaning coating liquid includes photocatalytically active semiconductor particles;

    (ii) third converting the aqueous-based self-cleaning coating precursor liquid into a self-cleaning layer, wherein, after the third converting step;

    (A) the self-cleaning layer is located on at least a portion of the inorganic barrier layer;

    (B) the photocatalytically active semiconductor particles are uniformly dispersed throughout the self-cleaning layer.

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